Encapsulated Underwater Vehicle Modules

ABSTRACT

An encapsulated module ( 14 ) for an unmanned underwater vehicle (UUV) (V) is formed with an operational component ( 16 ) and encapsulating material ( 60 ). The encapsulant ( 60 ) forms a rigid capsule surrounding the operational component ( 16 ). The capsule ( 14 ) has a least one exterior surface ( 18 ) that assists in forming the exterior surface ( 26 ) of the UUV (V) when the capsule ( 14 ) is combined into the UUV (V).

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates to the field of Unmanned Underwater Vehicles(UUVs) and more particularly to forms of such UUVs that are adaptable tomultiple mission profiles.

2. Background Art

Unmanned Underwater Vehicles (UUVs) are a well known tool used inmilitary and non-military operations. UUVs are currently designated fora single mission. Additionally, the high cost of development hinderstheir application for other purposes. UUVs are typically designed as ametallic pressure vessel with cables running from its extremities to thecentral processor. This results in an architecture that does not lenditself to be easily reconfigured for other purposed.

Exemplary UUVs are disclosed in U.S. Pat. Nos. 5,578,751; 5,786,545;6,058,874; 6,536,365; and 7,000,560.

Polyurethane potting has been used in conjunction with UUVs for sealingholes and individual cables against water intrusion as disclosed in U.S.Pat. No. 5,578,751; however, it is not known that a potting mixture hasbeen used to form part or all of the UUV itself.

The present invention enhances the functionality of the above citedpatents by utilizing a modular system to rapidly combine single ormultiple purpose or use modules into a fully functional UUV particularto the specific mission profile.

While the above cited references introduce and disclose a number ofnoteworthy advances and technological improvements within the art, nonecompletely fulfills the specific objectives achieved by this invention.

DISCUSSION OF INVENTION

In accordance with the present invention, an unmanned underwater vehicle(UUV) includes a steering unit for directional control of the UUV havingan exterior surface and at least one interchangeable module componentfor housing a desired operational unit appropriate for a chosen missionprofile. The interchangeable module has an exterior surface preferablyimpervious to the undesirable intrusion of water or other fluids. Afrontal portion may have an exterior surface that is adapted for flowthrough a fluid. The exterior surfaces of the steering unit, theinterchangeable module component and the frontal portion form asubstantially smooth surface envelope when the interchangeable module isattached to the steering unit and frontal portion for controlledmovement through a fluid.

The modules of the UUV V or the complete UUV V itself, as desired, maybe formed from an encapsulating material protecting the operationalmechanical and electrical components. The encapsulating materialprovides protection for the electronic and other operating componentsfrom water intrusion, crushing due to pressures on the module at a depthbelow the water surface, and other factors affecting the operability ofthe electronic components.

The present invention is a design for standardized UUV modules that canbe combined in any way to make an unmanned underwater vehicle. Thisstandardization allows the same technology to be used in multipleconfigurations. The reuse of technology significantly lowers the cost ofdevelopment of a UUV. Therefore, a module only needs to be designedonce, but can be reused in many vehicles with different purposes. Thepresent invention discloses standardized modules than can be combinedany way a user needs to make vehicles appropriate for a desired missionprofile.

These and other objects, advantages and preferred features of thisinvention will be apparent from the following description taken withreference to the accompanying drawings, wherein is shown the preferredembodiments of the invention.

BRIEF DESCRIPTION OF DRAWINGS

A more particular description of the invention briefly summarized aboveis available from the exemplary embodiments illustrated in the drawingand discussed in further detail below. Through this reference, it can beseen how the above cited features, as well as others that will becomeapparent, are obtained and can be understood in detail. The drawingsnevertheless illustrate only typical, preferred embodiments of theinvention and are not to be considered limiting of its scope as theinvention may admit to other equally effective embodiments.

FIGS. 1A and 1B are isomeric views of the modular UUV of the presentinvention.

FIG. 2 is a functional diagram of one form for a typical modular UUV ofthe present invention.

FIG. 3 is a perspective view of a rail system for assembly of themodules forming the competed modular UUV.

FIG. 4 is a perspective view of a truss assembly that may be used tojoin the modules.

FIG. 5 illustrates a tethered modular UUV of the present inventiondeployed from a control ship on the surface of a body of water.

FIG. 6 is a top view of a mold that may be used to form an encapsulatedmodular component of the UUV of the present invention.

MODES FOR CARRYING OUT THE INVENTION

So that the manner in which the above recited features, advantages andobjects of the present invention are attained can be understood indetail, more particular description of the invention, briefly summarizedabove, may be had by reference to the embodiment thereof that isillustrated in the appended drawings. In all the drawings, identicalnumbers represent the same elements.

The present invention relates to co-pending patent application entitled“Self Contained Underwater Vehicle Modules,” the disclosure of which isincorporated by reference herein as if fully set forth.

An unmanned underwater vehicle (UUV) V includes a steering unit orsegment 10 with an exterior surface 12 and at least one interchangeableoperational module component 14. The steering unit 10 functions toprovide for or assist in directional control or stability of the UUV V.The interchangeable module or modules 14 house one or more desiredoperational units 16 appropriate for a chosen mission profile of theimpervious to the undesirable intrusion of water or other fluids 20. Afrontal or nose cone portion 22 may by formed having an exterior surface24 that is adapted for flow through the fluid 20. The exterior surfaces12, 18, and 24 of the steering unit 10, the interchangeable modulecomponent(s) 14 and the frontal portion 24, respectively, form asubstantially smooth surface envelope or body 26 resembling a torpedoshape when the interchangeable module(s) 14 is attached to the steeringunit 10 and frontal portion or nose cone segment 22 for controlledmovement through the fluid 20.

Each module is designed and built to have a unique, single function(i.e. thrust, control, navigation, etc.). A vehicle V can be constructedof only the modules needed for a given mission profile. Additionalmodules 14 can be added or unnecessary modules 14 removed from thevehicle V with no impact. If a mission requires a particular attributeto be optimized or changed, that particular module 14 or sub-system canbe changed without redesigning the entire vehicle V. This independenceallows each function of the vehicle V to be added, removed, or upgradedby only replacing one section and establishing communications with otheroperational modules 14 as necessary. Different vehicles V can beconstructed of modules 14 with varying performance and cost based onmission requirements. FIG. 2 illustrates how each module 14 isself-sufficient and provides a single or multiple functions as desired.

The modules 14 of the present invention are self-contained andself-supporting, and vehicles V can be assembled from any number ofcompatible modules 14, in any order desired, to provide any lengthdesired. Each module 14 may provide a single function and may be fullycomplete for its desired information gathering or defensive functions.Preferably, a single interchangeable module 14 would include allnecessary electrical or mechanical components or arrays such as sensors28, processing 30. recording 32, communications 34, energy 36 or othersby way of example within each section or module 14 in order to improvereliability if one module 14 were to fail during a mission.

There is no minimum or maximum number of modules 14 required and eachcan operate independently or collectively. Each module 14 may beself-powered with its won energy component 36 and therefore not bedependent upon a common power bus subject to failure. Every module 14may have the same mechanical attachment in order that it can bepositioned in any sequence in the vehicle V as assembled.

Communication, either two-way or one-way, may be achieved over astandard or known protocol and architecture. Typically, communicationsmay be exchanged between individual interchangeable modules 14 or thesteering or propulsion unit 10 to exchange mission profile informationand information or intelligence that has been collected by the sensor 28or other operational components or arrays. Communication may be achievedwith the steering or propulsion segment 10 for independent directionaland stability control of the UUV V. Further, communications may beexchanged between the UUV V and a surface ship or supporting station 44either through a wireless connection using an antenna 38 or over atethered communication cable 40 extending between the support station 44and an attachment point 42 on the UUV V.

Also, while a typical vehicle V may have an internal wiredcommunications connection or bus 46, such as a known Ethernet form ofelectronic communication used for computing machinery, another vehicle Vmay communicate wirelessly through a known commercial Wi-Fi or radiofrequency technology, for example, with an appropriate internal (notshown) or external antenna 38 for data interchange between modules 14 orthe support station 44. Testing has been done to prove the viability ofthe wireless form of communication either between the modules 14 or fromone or more modules to the information collection point 44.

Each module 14 may be designed to be neutrally buoyant so the additionand subtraction of modules has no effect on the overall vehicle buoyancyat the desired mission profile operating depth.

Alternatively, one interchangeable module 14 may be formed to includethe nose cone or frontal portion 22 as is depicted in FIG. 2. A typicalsensor that may be mounted with the nose cone segment 22 is a camera toprovide visual assistance in guiding the craft V from the supportstation 44.

While the nose cone portion 22 is normally tapered or otherwise shapedto improve the movement of the UUV V through the water, the nose conemay even be a blunt surface. However, such blunt surface would notimprove the movement characteristics through water or other medium andlikely is not recommended to be used.

The steering or propulsion segment 10 generally includes a means ofpropulsion suitable for moving the UUV V through the water or otherfluid medium. A known propeller 48 or other known means for propulsionmay be selected. The cowling or exterior surface 12 of the propulsionunit 10 may have a tapered area or section 50 as necessary. Fins (notshown) or other means for steering the UUV V may be mounted with thesteering unit 10 or any other segment 14 to provide directional controland stabilizing control to the assembled UUV V.

Alternatively, if the UUV V is tethered as shown in FIG. 5, a separatepropulsion unit may not be needed and the section 14 that includes theattachment point 42 substitutes for or acts as the propulsion unit 10and directional control of the UUV V is predominately achieved throughmovement of the surface ship 44 that is towing the UUV V while it issubmerged. In such an alternative arrangement the UUV V can be solelyassembled from one or more interchangeable modules 14.

Each module 14, although scalable up or down, may be a 12″ diameter 52encapsulated segment, for example. Further, an optional outer coveringor surface 26 may be applied or used to encompass all the modules orsections for further streamlining of the modular UUV V in relation tothe fluid's characteristics during the mission. Such a covering could bea simple spray on material that is selected for radar reflection, soundabsorption or the like.

Each interchangeable module 14, propulsion or steering unit 10, and thenose cone 22 may have a cast U-channel 54 with pins 56 that enable themodules to slide onto a mechanical backbone 58 to form the completedmodular UUV V. Referring particularly to FIG. 3, a U-channel or rail 54is shown with pins 56 that slid onto the extrusion 58 to secure theindividual components or segments 10, 14, or 22 into the completed UUVV.

Alternatively, the modular vehicle V may have a truss system 60 as shownin FIG. 4 for each module or other component such as the propulsion unit10 or nose cone 22 that is connected with V-band clamps (not shown) orthe like at rings or edges 62 to join the individual selected modules orsections 10, 14, or 22 into the completed modular UUV V.

In addition to mechanical standardization, all electrical connectionsand connectors on the module are standardized as well. With standardizedof design, components, and processes there are reductions in costthrough quantity production of standard modules. Such a design yields areduction in cost that enables the first expendable UUV V.

Formation of an Encapsulated UUV Module

An encapsulated module 14 for an unmanned underwater vehicle (UUV) V isformed with an operational component 16 and encapsulating material 60.The encapsulant 60 forms a rigid capsule or module surrounding theoperational component 16. The capsule 14 has at least one exteriorsurface 18 that assists in forming the exterior surface 26 of the UUV Vwhen the capsule 14 is combined into the UUV V.

The modules of the UUV V or even the complete UUV V itself, as desired,may be formed from an encapsulating material protecting the operationalmechanical and electrical components. The encapsulating materialprovides protection for the electronic and other operating componentsfrom water intrusion, crushing due to pressures on the module at a depthbelow the water surface, and other factors affecting the operability ofthe electronic components.

The encapsulant, by way of example, may be a three part mixture 60,which is initially moldable and flowable, comprising a polyurethane 62(EN-9 from the manufacturer Conap may be used by way of example), glassmicrospheres 64 (K20 from 3M may be used for this component), and awetting agent 66 (Dow Corning 29, as example).

The mixture ratio of glass microspheres 64 and the types of glassmicrospheres may be altered as required to achieve the necessary densityappropriate for the cruising depth and pressure of the vehicle for theparticular mission profile. This three part mixture 60 is then used toencapsulate electronic components such as batteries 36 or otheroperational components 16, with seemingly few or no unfavorable effects.Typically, the encapsulant material 60 begins as a flowable liquid. Theoperating or desired components are placed in a mold 68 appropriate forthe desired outline of the UUV module. The encapsulating material 60 isthen poured into the mold 68 about the selected operating componentssuitable for the module being crafted. The encapsulant material 60 isthen left to dry or cure, which hardens the encapsulant material 60.

The mold 68 may be formed from paper or other materials compatible withthe encapsulant mixture 60 with provisions or cut-outs 70 excluding theflowable encapsulant material 60 from encroaching into the space for therail system 54 as shown in FIG. 3.

Additionally, the truss system 60 can be molded into the encapsulatedmodule to provide substantial strength and exceedingly rigidity whencombining the various modules into the UUV.

The suggested encapsulant has been used to create a sample vehicle Vwith an embedded single board computer and batteries. The sampleunmanned underwater vehicle V was pressure tested and this encapsulantwas found to protect the operational single board computer to 1050′ andthe batteries to 6750′ ft.

The formation of a module formed without undesired voids and from anessentially solid encapsulant eliminates or substantially reduces thechances of a crushing of the UUV module from the pressure about the UUVmodule resulting from the water/fluid column pressure above the UUV V.

The density of the encapsulated UUV module may be adjusted to provideneutral buoyancy for the UUV V at the selected operating depth whenconsidering other factors such as temperature and salinity at theoperating depth. Weighted spheres or other objects 72 may be added tomake the overall density of the encapsulated UUV module appropriate.Such weighted objects 72 can be formed from materials having a higher orlower density than the surround encapsulant material 60 to adjust theoverall density of the encapsulated UUV module to the desired value forthe assigned mission. Preferably the weighted objects 72 are rigidlyformed so as to not degrade the crush resistance of the encapsulated UUVmodule.

Depending on the type of encapsulating material used, it may be possibleto add a “dissolving” material to return the hardened encapsulatedmodule into a liquefied state thereby permitting the removal orretrieval of the operating component separate from the encapsulantmaterial 60.

The present invention is truly novel because of the design andmanufacturing techniques used. It advances the state of the art for UUVsystems and provides an architecture that could be used industry wide.The techniques described yield functionality, performance, andreliability that is unique for a typical unmanned underwater vehicle.The present invention produces a UUV that is less expensive tomanufacture than current systems.

Advantages of the present invention as compared to known devices includeimproved crush resistance for the UUV; a non-proprietary design, easilyreconfigured and upgraded, lower cost due to standardized componentsmaking the UUV; and, increased reliability due to a connectorless designand the resistance to the degrading impacts of water and pressure.

The foregoing disclosure and description of the invention areillustrative and explanatory thereof, and various changes in the size,shape and materials, as well as in the details of the illustratedconstruction may be made without departing from the spirit of theinvention.

1. An encapsulated module for an unmanned underwater vehicle (UUV)comprising: an operational component; encapsulating material forming arigid capsule surrounding the operational component; the capsule havingat least one exterior surface assisting in forming the exterior surfaceof the UUV when the capsule is combined into the UUV; and theencapsulating material further including weighted objects for adjustingdesired buoyancy of the UUV.
 2. The invention of claim 1 wherein thecompleted UUV is formed comprising a single module.
 3. The invention ofclaim 1 further including means for joining the encapsulated module withother encapsulated modules to form the UUV.
 4. The invention of claim 1further including means for conveying information out of the capsule toother capsules or a support station.
 5. The invention of claim 1 whereinthe encapsulating material is formed from a mixture of a polyurethanecomponent and a wetting agent component.
 6. The invention of claim 5wherein the weighted objects comprise beaded material.
 7. A method forpreparing an encapsulated module for an unmanned underwater vehicle(UUV) comprising: positioning an operational component into a mold;introducing an encapsulating material into the mold forming a rigidcapsule surrounding the operational component; the capsule having atleast one exterior surface assisting in forming the exterior surface ofthe UUV when the capsule is combined into the UUV; and, introducing intothe encapsulating material weighted objects for adjusting desiredbuoyancy of the UUV.
 8. The method of claim 7 wherein the completed UUVis formed comprising a single module.
 9. The method of claim 7 furtherincluding means for joining the encapsulated module with otherencapsulated modules to form the UUV.
 10. The method of claim 7 furtherincluding means for conveying information out of the capsule to othercapsules or a support station.
 11. The method of claim 7 wherein theencapsulating material is formed from a mixture of a polyurethanecomponent and a wetting agent component.
 12. The method of claim 11wherein the weighted obiects comprise beaded material.